Inkjet Ceramic Ink for Etched Glass Microstructure
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Solution Overview
Problem
Existing methods for producing an etched glass appearance through inkjet printing face issues such as imperfect appearance, process complexity, and final product properties, including excessive light transmission and abrasiveness, which hinder the creation of arbitrary patterns and desired microstructures.
Innovation Solution
A ceramic inkjet ink formulation comprising immiscible liquids and glass frit particles that self-organize during drying to form a phase-separated mixture, resulting in a non-abrasive, three-dimensional microstructure mimicking etched glass, achieved through a specific combination of glycerol, propylene carbonate, and a more volatile third liquid like solketal, which facilitates phase separation and stabilization of the glass frit particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional sandblasting or acid etching is used to produce frosted glass, then the glass surface achieves the desired opaque/translucent appearance with light scattering properties, but the process cannot produce arbitrary patterns without stencils or masks and is unsuitable for small quantities
Solution Approach 1:
The patent replaces mechanical sandblasting or chemical acid etching processes with a digital inkjet printing system that deposits ceramic particles directly onto the glass surface. This substitution enables arbitrary pattern creation without stencils while maintaining the light-scattering frosted appearance, resolving the contradiction between pattern adaptability and manufacturing simplicity.
Solution Approach 2:
The patent controls the size, concentration, and distribution parameters of ceramic particles in the ink formulation to achieve the desired frosted effect. By adjusting these parameters, the system can produce various degrees of opacity and different pattern densities, enabling versatile pattern customization while using a straightforward printing process.
2Manufacturing precision
If inkjet printing with particles up to 2 micron is used, then digital printing with arbitrary patterns is achieved, but the production of three-dimensional patterns required to mimic etched glass structure is not possible
Solution Approach 1:
The patent creates three-dimensional microstructure by controlling the vertical stacking and aggregation of ceramic particles in the ink layer. The particles are deposited in multiple layers with varying concentrations, forming height variations and three-dimensional relief structures that mimic the physical topography of etched glass, thereby adding the missing dimensional aspect to the otherwise two-dimensional printing process.
Solution Approach 2:
The patent uses composite ink formulations containing ceramic particles of different sizes, shapes, and refractive indices suspended in specialized carriers. This composite approach allows the ink to self-organize into three-dimensional structures during drying and firing, creating the complex microarchitecture needed to replicate etched glass optics while maintaining digital printing's pattern flexibility.
3Illumination intensity
If existing etch-effect inks with scattering particles or crystalline substances are used, then light diffusion is achieved, but the appearance is imperfect or the process is complex
Solution Approach 1:
The patent formulates the ink with ceramic particles and carrier components that automatically self-organize into light-scattering structures during the drying and firing processes. The particles spontaneously aggregate and stack to create the necessary microstructure for light diffusion, eliminating the need for complex post-processing steps or additional equipment while achieving the desired optical effect.
Solution Approach 2:
The patent utilizes phase transitions during the firing process, where the ceramic particles and organic carriers transform from a liquid ink state to a solid ceramic coating. This phase change enables the particles to sinter and form permanent three-dimensional structures that provide sustained light diffusion, simplifying the overall process by combining structure formation and optical effect creation in a single thermal treatment step.
4Object-affected harmful factors
If frosted glass is produced to enhance aesthetic appearance and privacy, then light transmission is reduced and glare is minimized, but the surface becomes abrasive and may leave marks
Solution Approach 1:
The patent creates a porous or cellular microstructure within the ceramic coating layer, where light is scattered and diffused by the internal pore structure rather than by surface roughness. This internal light scattering mechanism achieves glare reduction and privacy enhancement while maintaining a smooth external surface that resists abrasion and does not leave marks, thereby resolving the contradiction between optical performance and surface durability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The inkjet ink produces a non-abrasive, transparent, and non-markable frosted glass effect without additional processing steps, achieving the desired microstructure and optical properties, including reduced glare and enhanced privacy functionality.
Implementation Method 1
The third liquid is more volatile than the two immiscible liquids. Since the third liquid is more volatile than the first and second immiscible liquids, and evaporates faster than the two immiscible liquids, upon ink drying it supports the restoration of a phase-separated mixture of the first and second immiscible liquids.
Implementation Method 2
a first immiscible liquid, wherein the first immiscible liquid is selected from glycerol; water, optionally containing dissolved salts; ethylene glycol; propylene glycol; diethylene glycol; pentaerythritol; trimethylol propane; trimethylol ethane; a second immiscible liquid, wherein the second immiscible liquid is selected from propylene carbonate, dipropyl carbonate; tributyl phosphate; ethylhexyl acetate; isobornyl acetate; isoparaffins; aliphatic hydrocarbons; diethyl malonate, dimethyl malonate, and dipropylene glycol methyl ether acetate, wherein a mixture of the first and the second immiscible liquids is a phase-separated mixture
Data Source
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AI summary
Disclosed is an inkjet ink that is jettable through standard inkjet nozzles, yet creates a non-abrasive non-porous three-dimensional glass structure on a 1-100 micron-scale without the need for additional processes beyond those normally used for the inkjet decoration of glass substrates. Such an inkjet ink can avoid the drawbacks noted above and is described herein.